SOLARFOCUS ecotop zero User manual

Installation manual for qualified personnel
Read carefully before operating.
DR-0179-EN / v7-202109
Pellet boiler
ecotopzero,ecotoplight

1 About this manual
1 About this manual 2
2 Safety information 3
3 Technical specifications 3
3.1 Warranty, guarantee, liability 3
3.1.1 Technical specifications for warranty and gua-
rantee claims 3
3.1.2 Conditions for entitlement to benefits 4
3.1.3 Cessation of entitlements 5
3.1.4 Limitation of liability 5
3.2 Standards, guidelines, regulations 5
3.3 Installation room 5
3.4 Chimney, flue gas pipe 6
3.5 Supply air into the installation room 7
3.6 Room sealed appliance (RSA) 7
3.7 Filling water of the heating system 8
3.7.1 Avoid the formation of scaling 8
3.7.2 Avoid the corrosion on the water side 8
3.8 Notes on the hydraulic connection 9
4 Product information 10
4.1 Product description 10
4.2 Fuel 10
4.3 Scope of delivery 10
4.4 Accessories 11
4.5 Dimensioning of the boiler 11
4.6 Functional components 11
4.7 Safety devices 12
4.8 Dimensions and connections 13
4.9 Technical specifications 15
5 Installation 18
5.1 Transport 18
5.2 Dismantling the boiler door 18
5.3 Remove the pallets 18
5.4 Placing the boiler 18
5.5 Set adjustable feet 18
5.6 Removing the right-hand side panel 18
5.7 Dismantle upper cover 19
5.8 Establish RLU connection (optional) 19
5.9 Establish the chimney connection 19
5.9.1 Flue gas pipe: Hole for emission measurement 19
5.10 Connecting the pellet hose 20
5.10.1 Electrically earthing the pellet hose 20
6 Hydraulic connection 21
6.1 Piping in the boiler 21
6.2 Boiler connections 21
6.3 Install safety valve 22
6.4 Position mixer shaft, mixer motor 22
6.5 Fill the heating system 22
6.6 Bleed the heating system 22
7 Electrical connection 23
7.1 Voltage supply for the heating system 23
7.2 Connections to the boiler power element 23
7.2.1 Connect heating circuit pump(X9, X10) 24
7.2.2 Pellet conveyor system (X14) 24
7.2.3 External boiler request (X28) 24
7.2.4 Malfunction (X29) 25
7.2.5 External request (X51) 25
7.3 Cable ducts on the boiler 25
7.4 Install EMERGENCY OFF switch 25
7.5 Sensor resistance table 25
7.6 Electrical fuses 25
7.7 Connecting the control to the internet 26
8 Initial start-up 27
9 Shut-down 27
10 Annex 28
10.1 Boiler power element (image) 28
10.2 Overview of the electrical components 29
1 About this manual
Dear heating installer
To ensure reliable and efficient operation of the hea-
ting system, the following points are extremely import-
ant:
–Correct installation
–Training of customers in commissioning
–Comply with the specifications and instructions in
this manual
–Regular maintenance by the system operator
–Regular maintenance by qualified personnel
Language
The language of the original manual is German. Ver-
sions of this manual in all other languages are trans-
lations of the original.
Storage
Keep the manual for the entire service life of the pro-
duct and ready to hand. The manual must be passed
on to the new owner when the product is dis-
mantled/reused. If the manual is lost or destroyed,
request a new copy from the manufacturer.
Instructions and warnings
The instructions used in this manual are highlighted
with symbols and signal words. The signal word indi-
cates the level and nature of the danger.
2 Installation manual ecotop-zero, ecotop-light
Content

2 Safety information
iIndicates information for correct handling of
the product.
!CAUTION - Failure to comply with this instruc-
tion could result in damage to property.
DANGER - Failure to comply with this instruc-
tion poses a danger to people.
Manufacturer
SOLARFOCUS GmbH
Werkstrasse 1, A-4451 St.Ulrich
Company register no. 281755x
Tel.: [phone], Fax: [phone]
[email protected]
www.solarfocus.com
Service Hotline
–Email: [email protected]
2 Safety information
Qualification of personnel
–The work procedures described in this manual
must only be carried out by qualified specialist per-
sonnel.
–Work on electrical components must only be per-
formed by trained electricians and in accordance
with the relevant rules and directives.
Installation and commissioning
–System may only be installed and put into ope-
ration by qualified personnel (SOLARFOCUS ser-
vice technician or SOLARFOCUS service partner.
Keep unauthorized persons and children away
–Danger of burns due to hot lines and hot com-
ponents, risk of injury from mechanically moving
parts. Keep unauthorised persons away, do not
leave children unattended, and control access to
the boiler room and fuel storage room.
Safety devices
–Never disengage the safety equipment of the hea-
ting system. In case of failure, arrange for
immediate repair.
Maintenance and repair
–Perform maintenance activities at the specified
intervals. No or incorrect maintenance leads to
inefficient operation, higher failure risk of the boi-
ler and increased potential for hazards.
Recommendation: Conclude maintenance con-
tract
–Have repairs done by qualified personnel only.
Improper repairs can lead to risks for the user and
impaired operation.
–Store hot ashes only in metal containers. Never
put hot or warm ash in the dustbin. There is a
great danger of fire.
–For repairs use only original spare parts or parts
approved by the manufacturer (e.g. standard
parts).
Damage to the system
–If the electrical insulation (cables, plugs, switches)
becomes damaged, switch off the power supply
and have the insulation repaired.
–In the case of visible damage (e.g. thermal defor-
mation, mechanical damage) the operation of the
system must not be continued. The system may
only be operated if it is in perfect technical con-
dition.
3 Technical specifications
3.1 Warranty, guarantee, liability
Warrantyclaims apply within the framework of a boiler
maintenance contract.
3.1.1 Technical specifications for warranty
and guarantee claims
A prerequisite for the assertion of warranty and gua-
rantee claims is compliance with the following tech-
nical specifications.
Installation manual ecotop-zero, ecotop-light 3

2 Safety information
Regular maintenance and cleaning
–The boiler and the components of the heating sys-
tem must be maintained and checked regularly.
–This is the prerequisite
–for permanently reliable functioning of the boi-
ler,
–for energy-saving and environmentally friendly
operation of the boiler,
–for a long service life of the boiler.
–Option/Recommendation: Conclude maintenance
contract.
–Keyword documentation: In the course of main-
tenance by qualified personnel, the completed
activities/measures are documented in the main-
tenance log. It is recommended to keep a plant
logbook (for documentation/evidence purposes of
own activities), especially if specialist main-
tenance is not carried out.
Fuel
–The fuel used > 10must comply with the spe-
cifications.
–Unapproved fuel can lead to inefficient
combustion and can damage the boiler.
Specifications for the filling/supplementary
water of the heating system
–Control the pH value: must be between 8.2
and 9.5
–Avoid of stone formation > 8(=lime deposits on
heat exchanger surfaces):
–Pay attention to the water hardness
–Soften filling water, or better: desalinate.
–Avoid the corrosion on the water side > 8Cor-
rosion is usually triggered by the available oxygen
in the water):
–Correct system planning, correct dimen-
sioning, pay attention to material com-
binations.
–Repair leaks immediately.
–Expansion vessel > 9(prevents air suction
when the system cools down): Set pressure
correctly, check regularly.
–Existing underfloor heating: Attention with old,
diffusion-open plastic pipes > 9
Return temperature to the boiler
–A sufficiently high return temperature into the boi-
ler must prevent the temperature from falling
below the dew point (resulting in corrosion in the
boiler).
–This is ensured at ecotop zero/light by the inte-
grated return lift as standard.
Supply air to the boiler
–The supply air to the boiler must not contain any
aggressive substances. These can cause cor-
rosion in boiler and fireplace.
–Aggressive substances are, e.g. chlorine or fluo-
rine compounds (used in cleaning agents, sol-
vents, adhesives,...).
3.1.2 Conditions for entitlement to benefits
For warranty and warranty claims observe the fol-
lowing points:
–The warranty begins at the time at the time of han-
dover (delivery note, commissioning form).
–The warranty period is calculated from the date of
initial commissioning (according to the meter of
the operating hours of the control).
–The warranty periods are based on the relevant
regulations.
–We must be notified promptly and accurately of
any damage incurred, so that the cause can be
clarified.
–If the system has defects despite correct instal-
lation (in compliance with the technical docu-
mentation), we grant a warranty provided that the
system has been examined by the plant customer
service (commissioning form).
–The guarantee applies to technical, construction-
related faults and faults in the manufacture of the
system that prevent correct and problem-free
usage.
–We are not liable for parts that were not produced
by SOLARFOCUS. However, we are prepared to
assign our claims against the producer (con-
cerning this defect) to the buyer.
–In fulfilling the warranty/guarantee services, we
shall cover only the assembly time and the mate-
rials used, but not any travel or accommodation
costs necessary for the fitters/engineers or any
return transport costs.
–SOLARFOCUS GmbH assumes no liability for
any consequential costs of damages.
–The repair and/or warranty replacement shall be
carried out on site or in the SOLARFOCUS fac-
tory at our discretion.
–The company SOLARFOCUSwill determine whe-
ther such work requires a repair or whether the
parts are to be replaced free of charge.
4 Installation manual ecotop-zero, ecotop-light

2 Safety information
3.1.3 Cessation of entitlements
The maintenance, warranty and guarantee services
expire if one of the following points applies:
–Non-compliance with the technical requirements
> 3
–Damage during transport.
–Wilful damage.
–Damage due to force majeure (water, fire, etc.).
–Non-observance of information in the planning,
installation and operation manual.
–Insufficient energy or water, fault in the hydrau-
lics.
–Incorrect operation and failure to perform main-
tenance and cleaning as prescribed.
–Commissioning and maintenance carried out by
non-certified companies.
–Undocumented commissioning (missing com-
missioning protocol) and/or maintenance (main-
tenance protocol).
–It is almost impossible to produce flawless pain-
ted parts; for this reason, slight defects that do not
adversely affect proper use shall not be deemed
as grounds for complaint.
–No claims can be accepted under the warranty if
unauthorised intervention (or action that has not
been explicitly approved by us) has been carried
out. In addition, the goods must be paid for within
the specified payment timeframe.
3.1.4 Limitation of liability
SOLARFOCUS GmbH assumes no liability for injury
or material damage resulting from:
–Failure to observe the instructions in this manual.
–Use of the product for any purpose other than for
its intended use.
–Deployment of unqualified personnel.
–Use of non-approved spare parts.
–Technical modification of the product by the sys-
tem operator.
3.2 Standards, guidelines, regulations
The following bodies of regulations must be con-
sidered and adhered to during planning, installation
and operation of the heating system:
Standards for heating systems
–EN 303-5 - Part 5: Boilers for solid fuels, manually
and automatically fed firing systems, nominal
heat output up to 500 kW
–DIN EN 12828 Heating systems in buildings - plan-
ning for water-based heating systems
–EN13384- 13384 - Flue gas systems - thermal
and flow-based calculation methods- 1: Exhaust
systems with one fireplace
–ÖNORM H 5151 - Planning of central hot water
heating systems with or without hot water pre-
paration - Part 1:
–
–Simple inspection of combustion plants for solid
fuels
Standards for structural and safety installations
–TRVB 118 H - Technical Guidelines for Pre-
ventive Fire Protection (Austria)
–ÖNORMH 5170 - Heating systems - requi-
rements for construction and safety technology as
well as for fire and environmental protection
–ÖNORM M 7137 - Pressed natural wood pellets -
Wood pellets - Requirements for pellet storage at
the end-user
Standards for fuel
–EN ISO 17225-2 - Biogenic solid fuels - Fuel spe-
cifications and classes; Part 2: Classification of
wood pellets
–1. BImSchV - Federal Immission Control
Ordinance - Ordinance on Small and Medium
Solid-fuel Boilers()
Standards for the heating water
–ÖNORMH 5195-1 - Heat transfer media for buil-
ding services systems, Part 1: Preventing
damage from corrosion and scale formation in clo-
sed hot water heating systems(Austria)
–VDI 2035 - Prevention of damage in hot water
heating systems (Germany)
–SWKI BT 102-01 - Water quality for building ser-
vices installations (Switzerland)
–UNI 8065 (Italy)
3.3 Installation room
Structural specifications
–The boiler may only be installed in a dry, frost-free
room; the permissible room temperature is 5 to
30°C.
–The boiler may only be used on a sufficiently sta-
ble and non-combustible surface.
–Observe spacing to flammable materials (regional
regulations).
–Note the installation dimensions to ensure suf-
ficient space is provided (e.g. for service and
maintenance work).
–For normative specifications see ÖNORM H 5170
and guideline TRVB 118 H.
Installation manual ecotop-zero, ecotop-light 5

2 Safety information
Fire extinguishers
–Austria: A 6 kg ABC powder extinguisher is spe-
cified as the minimum requirement. Install it out-
side the boiler room in an easily visible and
quickly accessible place.
–Germany, Switzerland: In private homes, no fire
extinguisher is required for heating systems.
However, having a fire extinguisher is recommen-
ded.
Keep escape routes clear
–Under staircases, on escape routes and in unfi-
nished attics, the installation of fireplaces is inad-
missible.
3.4 Chimney, flue gas pipe
Chimney cross-section and chimney height
The necessary cross-section depends on the nominal
output of the heating system and the effective chim-
ney height (at least 6.5 m). We recommend that you
have the calculations performed by an expert.
Chimney execution
–The chimney must be resistant to moisture. Use
fire brick or stainless steel.
–The chimney must conduct away the flue gases
reliably at all times.
Connect the chimney condensate drain to the
sewage system
–Connect the condensate drain line of the chimney
to the domestic sewage system (to drain con-
densate, rainwater).
–Use DN 25 diameter pipe, install siphon.
Provide each boiler with its own chimney
–The boiler and the fireplace must be coordinated.
This is the only way to ensure the proper func-
tioning of the heating system and the correct
discharge of the flue gases.
–If there is only one chimney available for two boi-
lers, there is a risk (considering the different ope-
rating states of the boilers - full load/partial load).
This can lead to problems (e.g. the flue gas has
too low energy during the ascent, and does not lift
off sufficiently from the chimney mouth, ...odour
pollution by flue gases).
–Singly equipped chimneys are more reliable and
safer than multi-fuelled fireplaces.
Do not connect a gas boiler and blower boiler to
the same chimney
Do not connect a wood-burning stove and
blower boiler to the same chimney
–A wood-burning stove typically requires a larger
chimney diameter than the blower boiler.
–Acoustic disturbance from the blower boiler may
be possible in the living room (by the wood-
burning stove).
–Unnecessary risk due to gas leakage, e.g. if the
blower boiler is defective.
Execution of the flue gas pipe
–Run the flue gas pipe towards the chimney in
a short and rising direction, with as few chan-
ges of direction as possible.
–Change direction in the form of aerodynamically
favourable arcs, do not build kinks.
–The diameter of the flue gas pipe to the chimney
may be enlarged if required, but may not be redu-
ced.
–Place the inlet of the flue gas pipe in the chimney
just below the ceiling.
–The flue gas pipe must be tight. Seal seal-less
flue gas pipes on site with heat-resistant silicone.
Insulate flue gas pipe
–Insulate the flue gas pipe continuously from the
boiler to the chimney.
–Recommended insulation thickness: 50 mm rock
wool.
–Serves to prevent temperature loss and prevents
the consequential formation of condensation.
6 Installation manual ecotop-zero, ecotop-light

2 Safety information
Cleaning opening in the flue gas pipe
–To clean the flue gas pipe (e.g. removal of accu-
mulated fly ash) there must be an easily acces-
sible cleaning opening.
–Recommendation:Coordinate the number and
placement of the cleaning openings with the chim-
ney sweep.
Opening for emissions measurement in the flue
gas pipe
Make an opening (hole) in the flue gas pipe to per-
form the prescribed emission measurement > 19
Minimum draught requirement for boiler: 5 Pa
A draught stabiliser must be fitted if the specified
draught of 15 Pa is exceeded.
Install explosion damper
Abb. 2-1:Explosion damper integrated into draught limiter
iBefore longer horizontal pipe sections
(L>20xD) and at the high point before drop-
ping down the flue gas pipe, an explosion dam-
per must be installed, independent of the
boiler output.
For boiler outputs <50 kW, no explosion damper is
required (with short and rising flue gas pipe to the
chimney).
3.5 Supply air into the installation room
For Austria (according to standard H 5170):
–For the supply air, 2 cm² per kW thermal output of
the fuel, but allow at least 200 cm² free cross-sec-
tion. (Fuel heat capacity = boiler capacity / effi-
ciency)
–For the exhaust air, allow at least 180 cm² free
cross-section up to 100 kW nominal heat and an
additional 1 cm² free cross-section for every fur-
ther kW.
iCalculate at least a further 20 % for wire mesh
in the aeration cross-section.
For Germany In accordance with the Model Firing
Ordinance:
–For heating appliances with a nominal output of
up to 35 kW, a combustion air opening of at least
150 cm² or 2 x 75 cm² routed directly into the open
air must be provided.
–Alternatively, a door/window leading outside and
a room content of at least 4 m³/kW nominal heat
output are suitable. If the Aufstellraum does not
abut onto an outside wall, combustion air supply
via connecting rooms is possible. Here, the com-
bustion air is supplied via a sufficiently dimen-
sioned adjacent room which abuts onto an
outside wall.
–From 35 to 50 kW, provide a free aeration cross-
section of at least 150 cm². From 50 kW upwards,
for aeration and ventilation, provide a minimum
free cross-section of 150 cm² for each, plus 2 cm²
per KW in excess of 50 kW.
iCalculate at least a further 20 % for wire mesh
in the aeration cross-section.
Boiler
power
[In kW]
Minimum space [in cm²] including 20%
surcharge for grids
Austria Germany Switzerland
Supply
air
Exhaust
air
Supply
air/Exhaust
air
Supply air
20 kW
>240 >216
>180 >206
25 kW >180 >258
35 kW >180 >361
50 kW >228 >515
70 kW >228 >721
90 kW >276 >927
130 kW >347 >252 >372 >1339
200 kW >533 >336 >540 >2060
400 kW >1067 >576 >1020 >4120
3.6 Room sealed appliance (RSA)
iA room sealed operation of the ecotop zero/-
light is optionally possible. The connection for
the supply air line is integrated in the boiler as
standard > 19
Basic information
In conventional boiler rooms, the necessary supply
air openings from outdoors lead to uncontrolled heat
loss. This is prevented by using boilers that operate
independent of the room air, as the combustion air is
drawn directly into the boiler in from outside in sealed
supply air lines.
Installation manual ecotop-zero, ecotop-light 7

2 Safety information
RAI line integrated in chimney
The recommended variant: The intake air is taken in
from outside of the chimney pipe down to the boiler.
RSA line outside of the chimney
–Fire-rated insulation with rockwool required if the
RAI line passes through other rooms.
–Cold insulation of the RAI line within building ele-
ments (wall, floor, ...) required to avoid damage to
the building from condensate.
–Further information: standard EN 15287-2
►Establish the RSA connection > 19
3.7 Filling water of the heating system
Two essential points must be observed with regard to
the quality of the filling water (according to guideline
VDI 2035):
–Avoidance of stone formation (limescale)
–Avoidance of corrosion on the water side (caused
by oxygen in the heating water)
The lowest possible rate of corrosion of the installed
metallic materials can be achieved primarily if the
circulating water is located in the correct pH range
(8.2 to 9.5) , and if at the same time there is a low
electrical conductivity (50 to 100 µS/cm).
3.7.1 Avoid the formation of scaling
What is scaling
Scaling is the formation of firmly adhering deposits on
water-contacting walls of hot water heating systems.
This can subsequently lead to damage (stress cracks
in the metal, leakage).
Cause of scaling
The cause of scaling is the presence of limestone in
the water.
The following calculation/table determines the per-
missible total hardness of the filling water. If the
values are exceeded, the filling water must be trea-
ted, e.g. softened.
Calculation of the permissible total hardness of
the filling water
To determine the total allowable hardness for the sys-
tem, the specific water content must be determined:
System volume divided by total heating capacity
equals Specific system volume
1166 litres / 25 kW =46.64 l/kW Specific system
volume
Table:Permissible total hardness of the filling water
Total heat
output
Specific system volume (VDI 2035)
<20
l/kW
≥ 20 <50
l/kW
≥ 50
l/kW
< 50 kW ≤ 16.8°dH ≤ 11.2°dH < 0.11°dH
50 - 200 kW ≤ 11.2°dH ≤ 8.4°dH < 0.11°dH
20 - 600 kW ≤ 8.4°dH < 0.11°dH < 0.11°dH
> 600 kW < 0.11°dH < 0.11°dH < 0.11°dH
For example: if the total hardness of the filling water is
more than 11.2°dH, the filling water must be treated.
3.7.2 Avoid the corrosion on the water side
Corrosion is usually triggered by the available oxygen
in the water. This value can be brought into a safe
range with proper planning, design, installation and
maintenance of the heating system. A constant input
of oxygen should be avoided
Important in this regard:
–Expansion vessel > 9: Air suction during cooling
of the heating system must be prevented. Pay
attention to:
–Correct planning and execution of the expan-
sion vessel.
–Regularly check the system pressure, pre-
pressure of the expansion vessel.
–Immediately repair leaks in the heating system.
–In the case of underfloor heating systems of older
construction years, ensure diffusion-tight pipes >
9
Check the pH of the filling water
–The pH value must be between 8.2 and 9.5.
–If this pH value does not adjust itself after one
week in operation, it must be raised by adding 10
g/m³ trisodium phosphate (Na3PO4) or 5 g/m³
sodium hydroxide (NaOH). Allow 2 to 4 weeks of
operation before further corrections.
–Exception: If aluminium materials are used in the
heating system, a pH from 8.2 to 8.5 must be met
(pH> 8.5 increased corrosion tendency).
8 Installation manual ecotop-zero, ecotop-light

2 Safety information
Electrical conductivity
The probability of corrosion usually decreases with
decreasing electrical conductivity of the heating
water.
Low salt driving - filling with demineralised
water, see VDI 2035 sheet 2.
Low salt
Electrical conductivity at 25°C < 100 µS/cm
In the low-salt mode, the replenishment of water that
is not fully desalinated can significantly influence the
pH value and shift it into a critical range.
►Check the pH value regularly.
3.8 Notes on the hydraulic connection
Return flow boosting (RFB)
–Functioning: If cold heating water (temperature <
55°C) flows from the heating circuit/buffer tank
into the hot boiler, the steam contained in the flue
gas condenses on the "cool" boiler heat
exchanger surfaces. In the long term this leads to
corrosion and damage in the boiler. To avoid this,
hot water from the boiler flow is added to the
boiler return.
–Return booster modules with a motor-controlled
mixer perform this task more accurately and
reliably than thermally controlled modules.
–In addition, they allow the use of residual heat:
When the temperature in the buffer cylinder has
fallen to lower than that in the burner, the pumps
start up again, the return mixer opens, and the
residual heat from the boiler is transferred to the
buffer.
iThe ecotop zero/light has an integrated return
booster module; therefore no further mea-
sures are required in this regard.
Provide shut-off facilities in the pipes
–Position shut-off valves for each section (in buffer
tank, etc.) in order to minimise the quantity of
water that needs to be replaced in the event of
repairs or system extensions(: Avoiding the intro-
duction of oxygen, filling/supplementary water of
the heating system > 8).
Pressure compensation through expansion ves-
sel (ADG)
–The expansion vessel prevents air from being
sucked in when the system cools down (problem:
oxygen input, filling water of the heating system >
8)
–Dimension the expansion tank with a capacity of
12% of the total hydraulic system volume.
–Secure the expansion tank against shut-off. To do
this, either use the shut-off options on the way to
the expansion tank as cap valves, or unscrew the
hand lever (handwheel) and attach it to the expan-
sion tank with the wire in a clearly visible position.
–The installation of an expansion vessel or a pres-
sure maintenance system is mandatory. The use
of open expansion vessels is not permitted.
–The pressure in the heating system (readable on
the pressure gauge) and the pre-pressure set in
the expansion vessel must be checked regularly.
Attention with (older) diffusion-open plastic
pipes, e.g. existing underfloor heating system
–With older underfloor heating systems, the plastic
pipes, which are more open to diffusion, can lead
to increased oxygen ingress into the heating sys-
tem. This has a corrosive effect on components of
the heating system (keyword: Avoidance of cor-
rosion on the water side > 8).
–In this case, a system separation (by installing a
heat exchanger) must be carried out.
–Newer plastic pipes (approximately since the mid-
1980s) are diffusion-tight according to DIN 4726.
Buffer tank: Use, dimensioning
Advantages of installing a buffer tank:
–The boiler can always be operated in the optimum
load range. This leads to a longer boiler service
life and reduces emissions.
–Avoidance of unnecessary boiler start phases,
the higher fuel consumption during the start pha-
ses is significantly reduced.
–Heated water is continuously available in the buf-
fer tank for the heating circuits. This enables a
rapid heat supply to the heating circuits at any
time.
If the heating system is operated without a buffer
tank, the installation of a hydraulic separator > 9 is
required.
Dimensioning of the buffer tank:
For pellet boilers, a buffer volume of 30 litres per kW
heating output is recommended.
Hydraulic switch
–A hydraulic switch separates the flows in boiler
and heating circuits.
–If the heating system is operated without a buffer
tank, a hydraulic switch must be installed bet-
ween flow and return.
Installation manual ecotop-zero, ecotop-light 9

4 Product information
Install the dirt and sludge separator
–The separator removes circulating, magnetic and
non-magnetic free dirt and sludge particles (from
5 μm) from the heating system in fully automatic
continuous operation.
–Ensures the proper functioning of heat gene-
rators, thermostatic valves, heat exchangers in
the long term and reduces the risk of defects and
failures in the long term.
–Contributes to high-quality heating water, e.g.
also for existing systems.
4 Product information
4.1 Product description
–ecotop zeroThe ecotop light is a boiler for the com-
bustion of wood pellets
–The boiler has an automatic fuel ignition system,
automatic fuel supply and automatic cleaning of
the heat exchanger.
–The ash produced is collected in an ash box,
which must be emptied at regular intervals.
–The ecotop zero has an integrated electrostatic
dust collector.
–At ecotop light , this electrostatic dust collector
can be retrofitted on request.
4.2 Fuel
Pellets
Use wood pellets only in accordance with these spe-
cifications:
–Pellets according to the ISO 17225-2 standard,
class A1.
–Pellets that meet the additional ENplus certifica-
tion.
–Pellets that meet the additional DINplus certifica-
tion.
4.3 Scope of delivery
Qty. Designation
1 Boiler, preassembled
1 Return booster, integrated
2 Combustion grate
1 Needle nose pliers for combustion grate
1 Ash scraper
1 Ash pan
1Bag (transparent) with outdoor temperature sen-
sor
1 Flue gas pipe expansion from Ø100 mm to
Ø130 mm(Item 66556NIRO)
1 Operating manual
1 Installation manual
Not included in the standard scope of delivery:
–Boiler safety group (KSG)
–Pellet hose
–Chimney connection material
10 Installation manual ecotop-zero, ecotop-light

2 Safety information
4.4 Accessories
Lifting aid
–Optional accessories for carrying/moving the boi-
ler
–Item 6144
Abb. 2-2: Lifting aid mounted
Extension for exhaust pipe connection
–Accessory (included in delivery) for optional exten-
sion of the connection, from Ø100 mm to Ø130
mm.
–Can be used for flue pipe orientation upwards or
backwards.
–Art. 66556NIRO
►Establish the chimney connection > 19
►Specifications for chimney design > 6
4.5 Dimensioning of the boiler
The boiler must be correctly dimensioned in relation
to the heat distribution system behind it.
For a correct design, see calculations according to
standard EN 12828.
4.6 Functional components
1 Heating water, heating circuit (return/flow)
2 Flue gas pipe
3 Connections for pellets > 20
4 Induced draft fan
5 Suction turbine for pellets suction
6 Electrostatic dust filter (optional at ecotop light)
7 Intermediate pellet store
8 Boiler electrical power element > 23
9 Ash container
10 Rotary valve > 13
11 Differential pressure gauge
12 Heat exchanger with interior turbulators
13 Combustion grate
Installation manual ecotop-zero, ecotop-light 11

2 Safety information
4.7 Safety devices
Heat dissipation
–This function of the boiler control is a safety
device that prevents overheating of the boiler.
–Functioning: If the boiler temperature exceeds the
set Heat dissipation maximum boiler temperature,
all pumps relating to the energy consumer units
(e.g. heating circuit, DHW tank, buffer tank, etc.)
will be switched on and the heating circuit mixer
opened. In this way, energy is drained from the
boiler and it may be possible to prevent other
safety devices tripping.
–If the boiler temperature falls below the set Heat
dissipation maximum boiler temperature minus
1°C again, the pumps and mixers will be operated
in standard mode again.
[1] The parameter can be found in the Service menu |System
parameters button | General settings button.
Overtemperature reset (OTR)
–The safety temperature limiter (STL) is a safety
device that prevents overheating of the boiler.
–Functioning: The STL stops the heating process
at a boiler temperature ~95°C (exclusively elec-
trical function; fuel and air supply are interrupted).
–After tripping, the STL must be manually released
again by unscrewing the black sealing cap 1and
pressing the button as soon as the boiler tem-
perature falls below 60°C.
–If the safety overtemperature reset trips, this is
indicated in the boiler control display.
Abb. 2-3:Position of the overtemperature reset
Safety valve (to protect against excess pres-
sure in the system)
–The safety valve 1is a safety device for protecting
against overpressure in the water circuit of the
heating system.
–Functioning: The valve opens when the system
pressure exceeds 3 bar. Water/steam are dischar-
ged into an open drain via a discharge line, which
avoids consequential damage to the heating sys-
tem. The valve is closed during normal operation.
–For normative specification see EN 12828.
Abb. 2-4: Safety valve integrated into boiler safety group
►Install safety valve > 22
iThe safety valve (or a boiler safety group) is
not included in the boiler. On-site installation
required.
EMERGENCY OFF switch
–The EMERGENCY OFF switch is a manually ope-
rated safety device. The burner and the fuel sup-
ply to the boiler are stopped. Circulation pumps
remain in operation to dissipate heat and cool the
boiler.
–The switch must be installed outside the boiler
room in a safe place that is easy to access.
►Install EMERGENCY OFF switch > 25
12 Installation manual ecotop-zero, ecotop-light

2 Safety information
Rotary valve
The rotary valve fulfils all normative requirements for
the approved fuels regarding fire protection, burn-
back safety, backflow of gases.
Abb. 2-5:Rotary feeder for pellet transport
–Complies with requirements regarding burn-back
protection devices (BPD) according to TRVB 118
H.
–Prevents backflow of flammable products of com-
bustion into the fuel supply (according to EN 303-
5).
–Prevents spreading of fire into the fuel supply
(according to EN 303-5).
4.8 Dimensions and connections
Front
Back
Installation manual ecotop-zero, ecotop-light 13

2 Safety information
Side view
Top view - flue gas pipe connection aligned upwards
Top view - flue gas pipe connection aligned back-
wards
1 Boiler return
2 Boiler flow
3 Flue gas pipe
4 Pellet return air
5 Pellet suction
14 Installation manual ecotop-zero, ecotop-light

2 Safety information
Installation manual ecotop-zero, ecotop-light 15
4.9 Technical specifications
ecotop zero,ecotop light 15 20 24
Nominal heat output (NHO) [kW] 15.4 19.7 24.0
Heat output range [kW] 4.6 - 15.4 5.9 - 19.7 7.2 - 24.0
Energy efficiency class A+ A+ A+
Boiler class (according to EN 303-5:2012) 5 5 5
Boiler efficiency - zero - full load [%] 95.7 95.3 94.9
Boiler efficiency - zero - part load [%] 95.9 96 96.1
Boiler efficiency - light - full load [%] 93.8 93.5 93.2
Boiler efficiency - light - part load [%] 92.1 93.2 94.3
Dimensions
Width [cm] 60 60 60
Depth [cm] 66.5 66.5 66.5
Height (H)- incl.adjustable feet, adjustable feet
screwed at maximum depth of thread- without hydrau-
lic connections on the top of the boiler
[cm] 157.3 157.3 157.3
Minimum room height [cm] 185 185 185
Weight
Weight [kg] 280 280 280
Weight with wooden pallet [kg] 288 288 288
Water side
Water content [l] 55 55 55
Max. permissible operating pressure [bar] 3 3 3
Boiler flow/boiler return connection [”] 1” UN 1” UN 1” UN
Drain connection [”] AG 1/2 ” AG 1/2 ” AG 1/2 ”
Differential pressure at ΔT 10°K [hPa] 145 245 345
Differential pressure at ΔT 20°K [hPa] 35 60 85
Thermal overload protection [”] not required not required not required
Electrical connection
Connection, fuse protection 230 V AC, 50 Hz
C13 A
230 V AC, 50 Hz
C13 A
230 V AC, 50
Hz
C13 A
Fuel
Fuel
Wood pellets
acc. to
EN17225-2,
ENplus-A1
Wood pellets
acc. to
EN17225-2,
ENplus-A1
Wood pellets
acc. to
EN17225-2,
ENplus-A1
Capacity of intermediate pellet store [l] 55 55 55
Capacity of ash box [l] 20.3 20.3 20.3
Flue gas side
Flue gas pipe diameter [mm] 100/130 100/130 100/130
Height to centre of flue pipe [cm] 143 143 143
Flue gas mass flow full load [g/s] 9 / 10 12 / 12.5 15 / 15
Flue gas mass flow partial load [g/s] 3 / 4 4 / 4.5 5 / 5
Maximum flue gas temperature [1] full load [°C] 140 140 140
Maximum flue gas temperature [1] partial load [°C] 100 100 100
Minimum draught requirement [2] [Pa] 5 5 5
Condensation No No No

ecotop zero,ecotop light 15 20 24
Emissions according to test report - ecotop zero
Emission values [3] from the test report:Testing Insti-
tute / Test Report No.
TÜV SÜD
2219038-1
TÜV SÜD
2219038-2
TÜV SÜD
2219038-3
CO full load [mg/m³] 4 7 9
CO Partial load [mg/m³] 83 50 17
NOx full load [mg/m³] 111 114 116
NOx partial load [mg/m³] 107 109 111
Org. C full load [mg/m³] 0.3 0.6 0.9
Org. C partial load [mg/m³] 1.5 1.1 0.6
Dust content full load [mg/m³] 0.6 1 1.3
Dust content partial load [mg/m³] 0.5 0.9 1.3
Emissions according to test report - ecotop light
Emission values (related to 13% O2) from test repor-
t:Test institute / test report no.
TÜV SÜD
2220046-1
TÜV SÜD
2220046-2
TÜV SÜD
2220046-3
CO full load [mg/m³] 8 6 5
CO Partial load [mg/m³] 70 49 29
NOx full load [mg/m³] 112 113 114
NOx partial load [mg/m³] 106 108 110
Org. C full load [mg/m³] 1.7 2 1.9
Org. C partial load [mg/m³] 1.8 3 3.2
Dust content full load [mg/m³] 7.9 7 5.7
Dust content partial load [mg/m³] 6.3 8 9.1
Regulation (EU) 2015/1187 - ecotop zero
Nominal heating output [kW] 15 20 24
Energy efficiency class of the boiler A+ A+ A+
Energy efficiency class EEI Composite boiler and con-
troller A++ A++ A++
Energy efficiency index EEI of the boiler 121 121 122
Energy Efficiency Index EEI Composite Boiler and
Controller 125 125 126
Space heating annual efficiency etaS [%] 81 82 82
Annual emission values
CO - carbon monoxide [%] 98 58 22
NOX- Nitric oxide [%] 149 151 154
C - Total (carbon) [%] 1 1 1
Dust [%] 1 1 1
Regulation (EU) 2015/1187 - ecotop light
Nominal heating output [kW] 15 20 24
Energy efficiency class of the boiler A+ A+ A+
Energy efficiency class EEI Composite boiler and con-
troller A+ A+ A++
Energy efficiency index EEI of the boiler 118 119 121
Energy Efficiency Index EEI Composite Boiler and
Controller 122 123 125
Space heating annual efficiency etaS [%] 80 81 82
Annual emission values
CO - carbon monoxide [mg/m³] 83 58 35
NOX- Nitric oxide [mg/m³] 146 150 153
C - Total (carbon) [mg/m³] 2 2 3
Dust [mg/m³] 8 11 12
2 Safety information
16 Installation manual ecotop-zero, ecotop-light

2 Safety information
Installation manual ecotop-zero, ecotop-light 17
[1] Flue gas temperature can be adjusted electronically.
[2] A draught stabiliser must be fitted if the specified draught of 15 Pa is exceeded (Caution:In a boiler with room-sealed operation, use a
room-sealed independent draught limiter)

5 Installation
5 Installation
5.1 Transport
Option 1: Transport on pallet, with lift truck
The boiler is delivered factory-assembled on a single-
use wooden pallet.
Option 2: Transport with lifting kit
Lifting Kit
►Dismantle the 4 x mounting angles of the boi-
ler/pallet.
►Dismantle the boiler door > 18
►Mount the lifting kit (optional accessory) > 11 on
the boiler.
►Lift/move the boiler from the pallet.
5.2 Dismantling the boiler door
►Pull the tab 1below the fitting.
ÄThe hinge is released from the fixture.
Abb. 2-6
5.3 Remove the pallets
►Dismantle the 4 x mounting angles of the boi-
ler/pallet.
►Lift/move the boiler from the pallet.
iIf necessary, use carrying aid (optional acces-
sory) > 11
5.4 Placing the boiler
iObserve the placement of the boiler, the requi-
red minimum > 13
5.5 Set adjustable feet
►If necessary, adjust the adjustable feet on the
underside of the boiler .
Abb. 2-7
5.6 Removing the right-hand side panel
►Loosen 6 screws 1.
►Slightly lift the right-hand side part 2and remove
it from the side.
18 Installation manual ecotop-zero, ecotop-light

5 Installation
5.7 Dismantle upper cover
►Loosen the 4 screws
►Lift the cover on the right-hand side and remove
it.
Abb. 2-8
5.8 Establish RLU connection (optional)
►Feed the aluminium hose into the boiler at ope-
ning 2or 3and fit it at connection 1.
Abb. 2-9
Boiler-controlled room air damper in the RAI line
(optional)
Function: When the burner is switched off, the dam-
per closes to prevent any exchange of air inside the
RAI line.
Abb. 2-10: Control of a room air damper
►Connect the room air damper on the boiler power
element to X6 (230 V AC).
►For the parameter Reserve relay, select the
value External boiler.
The parameter Reserve relay is located in the Ser-
vice menu >External boiler.
5.9 Establish the chimney connection
See instructions for execution > 6
5.9.1 Flue gas pipe: Hole for emission mea-
surement
►Make the hole for the emission measurement
according to the following images (recom-
mendation according to standard).
►If these specifications cannot be implemented,
then make the measuring point after a calming
section, i.e. after the longest straight section of
the pipe. The tube orientation (horizontal, ver-
tical, oblique) plays no role in this case.
►In any case, place the measuring point before
any existing draught limiters.
You can find the function for carrying out the emission
measurement in the boiler operation manual,
keyword: Chimney sweep function.
Installation manual ecotop-zero, ecotop-light 19

5 Installation
Exhaust pipe horizontal
Exhaust pipe vertical
5.10 Connecting the pellet hose
Abb. 2-11
When installing the hose, observe the maximum per-
missible values.
Maximum hose length and delivery height
Routing
Max.
hose
length
Max.
delivery
height
Suction head to diverter for suc-
tion heads 10 m 1 m
Diverter for suction heads to boi-
ler 20 m 2.5 m
Total delivery path 30 m 3.5 m
Observe the following when installing hoses
–The hose must be attached to the floor at several
points (e.g. with perforated tape) to prevent it from
'floating' upwards (in the case of floor-mounting,
suction head).
–Route hose as straight as possible. To avoid sag-
ging, use SOLARFOCUS article support shell
made of zinc plated sheet steel.
–Do not kink the hose (observe bending radius of >
30 cm).
–The hose is not UV-resistant (routing outdoors is
not permissible).
–Temperature resistance of the hose < 60°C.
–Always push the end of the hose fully onto the
pipe connection as far as the stop. The hose will
slide on to the connection pipe better if you apply
a little water to the pipe.
–Tighten hose clamps firmly. Detachment of the
hose and the intake of false air must be reliably
prevented.
5.10.1 Electrically earthing the pellet hose
iA metal braid is integrated into the inside of
the plastic hose coil.
This metal braid must be electrically connec-
ted to the connecting pipe at each hose end
(for suction hose and return air hose).
Expose the strand and bend it into the hose
►Expose approx. 10 cm of the metal strand at the
end of the hose (remove any plastic sheathing
from the strand with wire strippers).
►Curve the metal braid and bend it onto the inside
of the hose.
►Push the hose over the metal connection pipe.
20 Installation manual ecotop-zero, ecotop-light